Step 1: recognize the scope of the task you are about to undertake (two months, full-time).

Study the difference between a Westie roof and a Vanagon roof (the Westie roof has a bedrail and a flat bar that are needed to support the bed and pop-top)...

Cross section of Westie roof showing bedrail.

Cross section of non-camperized Westie roof showing absence of bedrail (the donor van roof skin will provide this bed rail).

Skeleton of a Westie roof showing cross section of flat bar (bed rail) needed to support bed.

Where to cut your roof?

How to get the 'roof skin' and bed rail?

Rear support hinges:

The Westie roof also has two flat areas at the back of the roof that are needed to attach the hinges of the pop-top. Under each flat area (under the roof skin) is a flat support bar which provides reinforcement in supporting the weight of the pop top after the back support hinges are bolted onto your roof. These support bars (approx. 1 inch wide, 1 foot long, and 1/8" thick) can either be salvaged from the donor roof (lots of cutting involved) , or can be made out of a similar size metal bar -- in which case three holes will have to be drilled (of the correct diamater) in order to line up with the bolts on the hinges/supports). This is a very important step in the process (one that I did not fully understand until after it was too late. But Karl Bloss has documented it on his website: http://members.citynet.net/bloss/vw/poptop/index.html

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